Heavy Clutch/Hard Shifting/Broken Cables

[Warren]

Member
Posts : 109
Location : Ringwood East
  Heavy Clutch/Hard Shifting/Broken Cables

Hey SS & Justin

I have had a few problems similar to yours with Boris (Heavy Clutch/Hard Shifting/Broken Cables), which I have just fixed.

Some background:

Boris runs a Holden 202, with a 3 speed box that was very heavy on the clutch and crunched into reverse, and was difficult to select first & second.

A second broken clutch cable had me decide to replace the gearbox with a four speed and fit a new clutch.

In the process of pulling out the gearbox I checked the clutch release lever to find that one of the two riveted bolts that come in contact with the thrust bearing was gouged and warn down. The clutch was only about half worn, and the gearbox was OK.

The problem stemmed from the release lever (due to the wear) putting uneven pressure on the thrust bearing, which in turn put uneven pressure on the clutch diaphragm, which caused the pressure plate to whisk the clutch plate, spinning the input shaft, making gear selection difficult. Also the uneven pressure on the thrust bearing was causing the heavy clutch.

The original riveted bolts have a hole in the centre were a rubber bush sits, the job of these bushes is to keep the release lever centred on the thrust bearing. With only 1 or 2 mm of each bolt coming in contact with the thrust bearing. Worn rubbers meant that the lever twisted, allowing one of the bolts to slide down the face of the thrust washer, binding and further wearing the bolt.

The solution was to build up the two bolts with weld, then file them so that there was only 2 or 3 mm play with the thrust bearing and 4 or 5 mm of each bolt contacting the thrust washer.

Now with a new clutch & cable its like chalk and cheese, the clutch is so light it seems like no pressure at all is required to use the clutch, and gear changes are breeze.

Once again a simple fix makes all the difference.

Happy BUGA Warren